02B Gearbox how to do 5th Gear Upgrade

Hello everyone

My T4 2.4D has started jumping out of 5th Gear

Its an 02B Gearbox changed the oild not long ago and fitted the short shift conversion, could it be the engine mounts moving making it jump out or is it somthing internal ?

Seems to do it more when i'm towing or the first 10 miles of a trip.

thinking of fitting a Golf TDI 5th gear anyway which is longer gear.

thanks

 

Oil level is fine 2.5litres of Castrol's most expensive gear oil

 

Yes twice, i'll have another check tonite but its not loosing any oil, will also draing down and remove the cover to check the 5th Gear.

Here's a thread of changing the 5th for a Golf TDI 5th , could it be the selector shown that is at fault.

http://www.vwt4forum.co.uk/showthread.php?t=83109

 

5th Gear swap taken from T4 Forum, were i'm a member and this will be my next job.

This is how i did my 5th gear swap tutha day & the tools i used to do the job,,first off you will need a mate to help with foot on the brake pedal while in 5th gear for you to undo the main 2 gear bolts & again while you torque them back up
the old 5th gear ratio is
little gear 34 teeth big gear 44 teeth divide 34 by 44
which gives you a over all ratio = 0.772

the new gear ratio is small gear 32 teeth big gear 47 teeth which gives you a over all ratio of = 0.680
if your end cover is like this then you can do the conversion

this is as is when the cover is off & you need to remove the big spring clip to get the syncro out spring marks in red & the locating blocks marked in green,these hold the syncro together

syncro housing marked in red

undo the two 12 point bolts that hold the selector folk in place bolts marked red

unclip the spring & hold the housing whilst holding the 3 syncro blocks & slide the lot off the gear

the red section shows where i put the 2 leg puller & the green section show the part of the gear to heat up with a blow touch "Its A Must To Ease The Gears Off"
appily tension to the puller then give the gear a good old heating then apply more heat & so on

slightly better picture & you must put the gear bolts back in there threads while using the puller or you will damage the shaft threads

this is what it looks like once removed & note the red section marking the needle roller bearing,,again this will slide off know probs be careful its breakable,,also note iam getting the small gear warmed up ready for pulling,,again same method appies for pulling this gear as with the big gear

this is what i had to do to the puller to get it to fit in between the back of the gear & the gear box housing "Theres Know Other Way I Could Get In" picture shows one leg modded but you will ahve to mod both legs with the angle grinder & a "Slitting Disc"

I put the new samll gear in the oven for about 15 mins to get it hot & then hand fitted it then used the bolt to pull it home "Easy"
Its the syncro gear that needs heating then pulling home "Not" your new big gear,that can be fitted along with the needle roller first

this shows it all together,but i will try to explain the syncro blocks as i call them & the spring clip its riddly but do"able you need to slip them over the spring thats built into the syncro hub then sort of open them whilst fitting the spring clip they will resist thats how they work/hold it all together it sounds harder than it is,,once thats on fit the syncro folk,i got my mate to work the gear lever "Verrrry" slowly sort of going for 5th but not just to aid the selctor folk then once she is in bolt her up & get ya mate to select 5th if the syncro hub goes inwards towards the gear box your cooking on gas,,i got him the go for 5th at least half dozen times till i was happy with how it looked & sounded.
i bought one of these sets knowning i did "Not" want to get stuck,i paid 42 for it but it will come in handy for other jobs on the van


sorry about the pics "Mobile Phone"
note the bit on the left as 6 points & the bit on the right as 12 points

folk think torx are torx there not,this kit as 3 different types & your Vw T4 van gear box uses two of them
the torque settings are as follows
the 2 gear bolts
T60 Bit @ 59 ft-lbs
Folk arm Selector
M8 Bit @ 18 ft-lbs
part numbers
Small Gear 02D 311 361
Big gear 02D 311 158
195 from Vw & worth every penny
i also drained the gear box & refilled with 75W90 semi synthetic 2.5 Lts,,looks like veg oil tonnes better than the black contaminated stuff that came out.
right i hope ive got everything sorry if ive missed anything,Oh forgot put it in 5th gear foot on brake to undo & same again when tightening
she now sits at
60 mph 2300 rpm
70 mph hair over 3000 rpm
85 mph 3500 rpm iam running 205/55/16 tyres which will improve this but all in all well worth it,she will trundle along with traffic at 30 mph in 5th just

 

Good post. How were your old gears? Are they up for sale? Would like to do this to mine.

 

Same as the 02a/j, always a ***** getting either the hub or small gear off, especially when the small gear is on the large side and you can't get a pulled in there.

 

Martyn havn't done mine yet, but would you know why its jumping out of 5th at the moment while driving ?

cheers

 

100k of easy driving, but jumping out of 5th at the moment so i am trying to find out why at the moment.

 

Just read the top of that post and realised you hadn't done it.

 

Took the T4 out for a drive today and lost all drive in 5th gear , its been jumping out of 5th gear and making





so i'm in search for a TDI 5th Gear to replace the damaged gears. new gear ratio required is small gear 32 teeth big gear 47 teeth which gives you a over all ratio of = 0.680

 

Found this link for the parts , but looks like i'll get them new from the main dealers if i can't get some from an old box.

http://www.idparts.com/catalog/product_info.php?cPath=99&products_id=520

either that or i'm driving to the Pod next week in 4th all the way with the trailer on.


here's a good "how to do 5th gear " thread.

http://www.myturbodiesel.com/1000q/multi/5th-gear-swap-VW.htm

 

O2A ratios:
_________1st___2nd___3rd___4th___5th___R&P___Notes
ATA====3.778 =2.105 =1.345=0.971=0.795=3.684==Corrado G60

AYL====3.778=2.118=1.429=1.029=0.837=3.684==Corrado G60

CAW====3.77=2.118=1.458=1.034=0.838=3.647==Corrado G60

CDM====3.300=1.944=1.308=1.034=0.838=3.647==Corrado VR6

AGC====3.778 =2.105=1.345=0.971=0.795=3.944= Passat 16V

AYK====3.778=2.118=1.429=1.029=0.837=3.684= Passat 16v

CES====3.778=2.118=1.429=1.029=0.837=3.684== Passat?

CHA====3.778=2.118=1.360=0.917=0.717=3.944==VR6 Canada

CGY====3.778=2.118=1.458=1.029=0.837=3.684== Passat?

CNL====3.778=2.118=1.458=1.029=0.837=3.684==VR6 Passat?

CCM====3.300=1.944=1.308=1.034=0.838=3.389==VR6 Passat, Jetta, Golf

CTN====3.778=2.118=1.360=1.029=0.755=3.157==Jetta/Golf/Passat TDI Beware these have 02J style output flanges. I've heard that people need to order 02J diffes for them. I'll know soon as I have one for my TDI Corrado and I plan to install a peloquin.

DQY====3.778=2.118=1.360=1.029=0.755=3.389==Jetta/Golf TDI

ASD====3.300=1.944==1.308==1.09==0.717==3.16==TDI I've heard of a few being bought in the USA but I believe its a euro MK3 TDI tranny

CHN==== Golf

CHU==== 4.24 R&P and its from a 2L Passat

CRU====3.300=1.944=1.308=0.971=0.755=4.24===B4 Passat ABA

CDA====3.30==1.944=1.308=1.029=.838=3.68===MK3 ABF (euro 2L 16V)

O2C trannys (SYNCRO):

CBC,CHD=3.778=2.118=1.360=0.967=0.769=3.938== Passat Syncro CDN

AYR ====3.778=2.118=1.345=0.971=0.756=3.944== Passat Syncro

CDH====3.778=2.118=1.360=0.967=0.769=3.938== Passat Syncro

Ok here are the Part numbers for the different 5th gears

For the .755 gearing you'll need:
02a311361Q is $142.77
and 02a311158E is $226.05

For the .717 gearing you'll need:
02a311361M is $142.77
and 02a311158R is $226.05


Some 02J tranny codes provided by a kind Vortexer that looked them up on his bentley
1.8T trannys coded: EBQ, EMT, EGX, FBW:
_1st___2nd___3rd___4th___5th___R&P_
3.300-1.944-1.308-1.029-0.837-3.938

TDI trannys coded: DQY, EBJ, EGR:
_1st___2nd___3rd___4th___5th___R&P_
3.788-2.118-1.360-0.971-0.756-3.389

2.0 trannys coded: DZQ, EBP, EGT, EKG, EKH, EMS, EZK, FBV:
_1st___2nd___3rd___4th___5th___R&P_
3.778-2.118-1.360-1.029-0.837-4.235

VR6 trannys coded: DZC, EHC, EGF, EWW, FBY, FCF
_1st___2nd___3rd___4th___5th___R&P_
3.625-2.071-1.474-1.038-0.844-3.389


1.8T trannys coded: EHA
_1st___2nd___3rd___4th___5th___R&P_
3.300-1.944-1.308-1.029-0.837-3.65

The EHA gearing is confirmed by Bentley:

 

Brookster. Is there Any T4 owners you know have done this? Maybe their old 0.755 gears are for sale for me?

 

Yes there are aload on T4 Forum


http://www.vwt4forum.co.uk/forumdisplay.php?f=18

 

Can't see anything on that link.

 

Looks like the 5th gear end is a little cooked, the cause of the jumping. Due to the way the box is designed if the oil level gets low it starves the 5th gear end, and basically burns it out. It jams up and starts to wear the gears out due to excessive contact.
If you've lost teeth then it'll need a strip down and clean out to check for other damage incase it's gone throughout the box.

 

Thanks Martin

The lack of oil was due to the garage who did the clutch, i will be going to see them this week.

I've cleaned out the box and everything esle looks ok.

also looks like i have found the 02A 311 361 Gear.

and i will have to order the 02D 311 158 Gear from the dealers.